Method and apparatus for wireless remote control communication of a welder

ABSTRACT

A method and apparatus of communicating control signals to a welding power source from a remote location includes a welding system operated by control signals transmitted by a wireless remote control that can be remotely located from the welding power source. A plurality of welding parameters in the welding system are set and adjusted in response to wireless command signals transmitted to a receiver that is connected to the welding power source via a connection port and is further connected to a controller in the welding power source. In this regard, an operator is able to quickly and efficiently control a welding system from a remote location, with no more cables than are necessary to perform the intended task.

BACKGROUND OF THE INVENTION

The present invention relates generally to welding machines and, moreparticularly, to a method and apparatus of communicating control signalsto a welding power source from a remote location. Specifically, theinvention relates to a welding system whose operation is governed bycontrol signals transmitted by a wireless remote control. A plurality ofwelding parameters in the welding system are set and adjusted inresponse to wireless command signals received by the welding powersource. In this regard, an operator is able to quickly and efficientlycontrol a welding system from a remote location, with no more cablesthan are necessary for welding.

Welding and cutting are essential operations in many different areas ofmanufacturing and construction in today's economy. The versatility andefficiency of welding and cutting systems is vital to, and allows for,the efficient completion of many complex and dynamic welding operations.In many welding and cutting processes performed by operators,welding-type systems are adjusted during the process to accommodateseveral different welding-type operations. When the need for suchadjustments arise, the welding parameters in the welding-type systemneed to be properly set for each different welding-type process. In eachof these processes, parameters need to be set and adjusted prior to andduring the welding-type process. In many instances, the welding-typeprocess takes place at a distance from the actual welding machine/powersource. Thus, an operator is required to walk back to the machine tomake any necessary adjustments. To overcome this problem, somewelding-type systems have started to incorporate some form of remotecontrol. In many existing systems, power and communications between anoperator location and a welding-type power source location aretransmitted over cables. These cables provide a simple and reliablemeans for communication and control of various welding parameters.

Despite the benefits of such a set-up, there are also numerous drawbacksassociated with communication and control of the welding-type system insuch a manner. One drawback to this cable-based control is that thecommunications cable is typically fragile relative to the welding cablesdesigned to carry high currents at high voltages. Welding-type systemsare often used at sites where it is not uncommon for the systems to beperiodically relocated or surrounded by other mobile heavy equipmentoperating in the same area. As such, the remote control communicationscable can become damaged by being crushed or snagged from contact withsurrounding machines and/or traffic. This can cause damage to thewelding-type power source if internal power conductors become shorted tosignal leads that are connected to sensitive signal level circuitry andobviously reduce productivity.

Communications cables for remote control of a welding device alsoproduce additional concerns. One of these concerns is the introductionof high frequency electrical noise to the welding-type system, whichoccurs because of the high voltages present in the environmentsurrounding the communications cable. The communications cable providesa conduit for the noise to enter the power source and controller of thewelding-type system. This noise and interference must be filtered out soas not to negatively affect the performance of the system.

Because of the numerous drawbacks associated with communication cablesfor remote control of a welding-type system, attempts have been tomodify the manner of communication in newer systems. Various types ofremote control devices have been introduced to facilitate operatorcontrol of the welding-type processes thru a means other than just astandard communications cable. However, while newly designed systems canbe designed to include such wireless remote control devices, a problempersists regarding existing welding systems not currently configured toallow for operation via a wireless remote control. Therefore, a needremains for a system able to retrofit an existing welder with a remotedevice capable of controlling a welding operation in a manner that ispractical and efficient for an operator.

A remote control device that can be incorporated into existing weldingsystems and that can wirelessly control a plurality of welding processesis a feature that would greatly enhance the productivity of existingwelding systems. Eliminating the communications cord with a wirelessremote control would overcome many of the problems associated with highfrequency electrical noise as described above. A wireless remote controlwould also provide for many benefits and conveniences for an operator,such as reducing the inconvenience of extra cables. Removal of acommunication cord also would eliminate the possibility ofcommunications being damaged due to sparks, hot metal and heavy objectsfalling on the cord and increase portability of a welding system. Theelimination of extra cords also would allow for more convenient use ofthe welding system in confined areas.

BRIEF DESCRIPTION OF THE INVENTION

The present invention overcomes the aforementioned drawbacks and addsthe stated benefits by providing a welding-type system capable ofwirelessly controlling various welding parameters from a remotelocation. The welding-type system includes a welding power source havinga controller, a welding torch, a wireless remote control capable ofcontrolling a plurality of parameters in a welding system, and areceiver.

Therefore, in accordance with one aspect of the present invention, awelding-type system is disclosed that includes a power source having acontroller to regulate welding operations and a welding torch connectedto the power source. The system also includes a wireless remote controlconfigured to remotely transmit a signal for controlling a plurality ofwelding parameters in the welding system, and a receiver remote from thewireless control and configured to receive the signal and allow thecontroller to regulate at least one of the plurality of weldingparameters in response thereto. The receiver is further configured toengage a connection port located on the power source, the connectionport configured to engage both the receiver and a control cable.

In accordance with a further aspect of the present invention, a wirelessremote control kit for retrofitting a welding-type apparatus isprovided. The wireless remote control kit includes a wireless controlconfigured to transmit a signal to control a plurality of weldingparameters in a welding-type apparatus suitable for producing awelding-type power. The wireless remote control kit further includes areceiver remote from the wireless control and configured to receive andrelay the signal to the welding-type apparatus. The receiver isoperatively connected to a controller housed in a power source of thewelding-type apparatus.

According to yet a further aspect of the invention, a method foradapting an existing welding-type system for use with a wireless remotecontrol is disclosed. The method includes the steps of connecting areceiver to a welding-type power source by way of an existing controlcable connection port, wirelessly transmitting a signal from thewireless remote control indicative of desired operational parameters ofthe welding-type system, receiving the signal remotely by way of thereceiver, and controlling the welding-type system in accordance withdata embodied in the received wirelessly transmitted signal.

Various other features and advantages of the present invention will bemade apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate one preferred embodiment presently contemplatedfor carrying out the invention.

In the drawings:

FIG. 1 is a perspective view of a welding-type system and remote controlcommunication system for controlling a welding-type device according tothe present invention.

FIG. 2 is a perspective view of the welding-type system of FIG. 1 and adetailed view of a connection port thereon.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows a welding-type system capable of performing various typesof operations. The welding-type system 10 is merely representative of awide variety of welding-type machines having various sizes, features,and ratings. The welding-type system, as contemplated herein, can beconfigured to not only perform standard welding type operations such asTIG, MIG, and/or stick welding, but can also be capable of performingvarious cutting operations that are closely associated with the variouswelding procedures, such as plasma cutting for example. In the exemplaryembodiment of FIG. 1, the welding-type system shown is preferably atungsten inert gas (TIG) welding system, however, one skilled in the artwill readily appreciate that it may be any related welding or cuttingsystem, including those listed above. TIG welding system 10 includes apower source 12 to condition raw power and generate a power signalsuitable for welding applications. Power source 12 includes aprocessor/controller 13 that receives operational feedback and monitorsthe operation of TIG welding system 10. Connected to power source 12 isa torch 16 via a cable 18. Cable 18 provides torch 16 with power andcompressed air or gas, where needed. Torch 16 includes a handle portion29, or torch body, having a trigger 31 thereon to actuate the torch andwork tip 32 extending therefrom.

Also connected to power source 12 is a work clamp 20 which is designedto connect to a workpiece (not shown) to be welded and provide a returnpath. Connecting work clamp 20 to power source 12 is a cable 22 designedto provide the return path for the welding current from torch 16 throughthe workpiece and work clamp 20. Extending from a rear portion 23 ofpower source 12 is a power cable 24 having a plug 26 for connectingpower source 12 to either a portable power supply (not shown) or atransmission line power receptacle (not shown). Also connected to thepower source is a gas source 33 configured to supply a gas flow to thewelding torch 16.

To allow for wireless operation of the welding-type system 10 from alocation remote from power source 12, wireless remote control 50 andreceiver 36 are included in welding-type system 10 and configured to setand adjust operational parameters therein. Wireless remote control 50 islocated remote from the welding-type power source 12 during awelding-type operation and communicates with receiver 36. Receiver 36 isoperatively connected to controller 13 and welding-type power source 12and is configured to receive and relay wireless signals from control 50to controller 13 to process the received wireless data. In this manner,wireless remote control 50 controls operation of the welding-type system10 and sets or adjusts the various welding-type parameters.

As shown in FIG. 1, receiver 36 is specially constructed to interconnectto an existing connection port 37 of welding-type system 10. In additionto interconnecting with receiver 36, connection port 37 is alsoconfigured to engage standard control cables (not shown) often used in awelding system. As receiver 36 is constructed to engage connection port37, older welding-type systems not capable of control via a wirelessremote device can be easily modified (i.e., retrofitted) to incorporatereceiver 36 and wireless remote control 50 of the current invention. Inone embodiment of the current invention, receiver 36 can be constructedto connect to welding-type power source 12 by way of an existing 14-pinconnection port 37 located on the front panel 42 of power source 12.Preferably, receiver 36 is operable with either AC or DC power, and overvarious control voltages, at least ranging from 5V to 24V. An exemplarycontrol circuit having a wide voltage window is preferred to achievethis functionality.

Various means of communication can be used to transmit signals fromwireless remote 50 to receiver 36. In a preferred embodiment, radiocontrol (RC) signals are used. However, other means of communication caninclude, but are not limited to, radio frequency (RF), cellular digitalpacket data, high speed circuit switched data, packet data cellular,general packet radio service, radio transmission technology, Bluetooth,IrDA, multi-channel multipoint distribution service, local multipointdistribution service, WiMAX, 802.11 Wi-Fi, infrared, UHF, VHF, and RIM.It is recognized that the mode of communication selected will depend onthe specific needs of the welding-type process and on the environment inwhich the process is being performed in.

As shown in FIG. 1, it is envisioned that wireless remote control 50 bein the form of a foot pedal control, a handheld control, or a fingertipcontrol; however, such embodiments are not meant to limit the form ofthe wireless remote control 50 that can be used in the presentinvention. A wireless remote control 50 in the form of a foot pedalcontrol, fingertip control, or handheld control, can include a switch(not shown) or other similar device thereon that allows an operator toeasily adjust and control one or more welding parameters in welding-typesystem 10. These controllable welding parameters can include, but arenot limited to, current, voltage, inductance, and pulse commands.

The specific welding parameter that is controlled by wireless remotecontrol 50 is determined by an operator via a front panel control 42 onpower source 12. Front panel control 42 is of a design well-known in theart, and includes a plurality of adjustors and selectors thereon. Theexact mechanisms found on front panel control 42 can vary, but willallow an operator to select the specific welding parameters to becontrolled by wireless remote control 50.

As stated above, not only can a welding-type system 10 be designed withthe wireless remote control 50 and receiver 36, but it is alsoenvisioned that existing welding-type systems can be modified with anassembly kit, to allow for wireless remote control of the system. Awireless remote control assembly kit (not shown) can be integrated withan existing welding-type system by operatively connecting receiver 36with controller 13 of the welding-type power source 12 via an existingconnection port 37. Wireless remote 50 is then configured to communicatewith receiver 36. Receiver 36 is configured to receive and relaywireless signals from control 50 to the controller 13 to process thereceived wireless data so as to control operation of the welding-typesystem 10 and set or adjust the various welding-type parameters.

As one skilled in the art will readily appreciate, the aforementioneddescription of welding-type systems not only includes welders, but alsoincludes any system that requires such enclosures and/or high poweroutputs, such as heating and cutting systems. Those skilled in the artare well acquainted with such welding-type devices, and as used herein,the term is given its ordinary meaning to those skilled in the art ofwelding and cutting apparatus.

Therefore, the present invention, including welding-type systems, isequivalently applicable with any device requiring high power output,including welders, plasma cutters, induction heaters, and the like.Reference to welding power, welding-type power, or welders generally,includes welding, cutting, or heating power. Description of a weldingapparatus illustrates just one embodiment in which the present inventionmay be implemented. The present invention is equivalently applicablewith many high power systems, such as cutting, or any similar systems.

Therefore, in accordance with one embodiment of the present invention, awelding-type system is disclosed. The welding-type system includes apower source having a controller to regulate welding operations and awelding torch actuated by a trigger and connected to the power source.The system also includes a wireless remote control configured toremotely transmit a signal for controlling a plurality of weldingparameters in the welding system, and a receiver remote from thewireless control and configured to receive the signal and allow thecontroller to regulate at least one of the plurality of weldingparameters in response thereto. The receiver is further configured toengage a connection port located on the power source, the connectionport configured to engage both the receiver and a control cable.

According to another embodiment of the present invention, a wirelessremote control kit for retrofitting a welding-type apparatus isprovided. The wireless remote control kit includes a wireless controlconfigured to transmit a signal to control a plurality of weldingparameters in a welding-type apparatus suitable for producing awelding-type power. The wireless remote control kit further includes areceiver remote from the wireless control and configured to receive andrelay the signal to the welding-type apparatus. The receiver isoperatively connected to a controller housed in a power source of thewelding-type apparatus.

According to a further embodiment of the invention, a method foradapting an existing welding-type system for use with a wireless remotecontrol is disclosed. The method includes the steps of connecting areceiver to a welding-type power source by way of an existing controlcable connection port, wirelessly transmitting a signal from thewireless remote control indicative of desired operational parameters ofthe welding-type system, receiving the signal remotely by way of thereceiver, and controlling the welding-type system in accordance withdata embodied in the received wirelessly transmitted signal.

The present invention has been described in the terms of the preferredembodiment and it is recognized that equivalents, alternatives, andmodifications, aside from those expressly stated, are possible andwithin the scope of the appending claims.

1.-16. (canceled)
 17. A welding-type system comprising: a welding-typepower source having a controller to regulate welding operation; awireless remote control configured to remotely transmit a signal forcontrolling at least one of a plurality of welding parameters in thewelding-type system; and a wireless receiver connected to the controllerremote from the wireless remote control and configured to receive thesignal and allow the controller to regulate at least one of theplurality of welding parameters in response thereto, wherein thewireless receiver is configured to engage an existing welding-typecontrol cable connection port located on an exterior of the welding-typepower source.
 18. The welding-type system of claim 17, wherein theexisting welding-type control cable connection port is a 14-pinconnector.
 19. The welding-type system of claim 17, wherein theplurality of welding parameters includes current, voltage, inductance,and pulse commands.
 20. The welding-type system of claim 17, wherein thewireless receiver is operatively connected to the welding-type powersource and the controller to relay signals therebetween.
 21. Thewelding-type system of claim 17, wherein the wireless remote controlcommunicates with the wireless receiver via one of a radio control (RC),radio frequency (RF), cellular digital packet data, high speed circuitswitched data, packet data cellular, general packet radio service, radiotransmission technology, Bluetooth, IrDA, multichannel multipointdistribution service, local multipoint distribution service, WiMAX,802.11 Wi-Fi, infrared, UHF, VHF, and RIM.
 22. The welding-type systemof claim 17, wherein the wireless remote control is configured to be oneof a handheld control, a footpedal control, and a fingertip control. 23.The welding-type system of claim 17, wherein the existing welding-typecontrol cable connection port is configured to engage both thewelding-type control cable and the wireless receiver via matching maleand female connectors.
 24. A wireless remote control kit comprising: awireless control configured to transmit a signal to control a pluralityof welding parameters in a welding-type apparatus suitable for producinga welding-type power; and a wireless receiver remote from the wirelesscontrol and configured to receive and relay the signal to thewelding-type apparatus, wherein the wireless receiver is configured tobe operatively connected to a controller housed in a welding-type powersource of the welding-type apparatus by connection to an existingwelding-type control cable connection port located on an exterior of thewelding-type power source.
 25. The wireless remote control kit of claim24, wherein the existing welding-type control cable connection port is a14-pin connector.
 26. The wireless remote control kit of claim 24,wherein the wireless control is configured to be one of a handheldcontrol, a footpedal control, and a fingertip control.
 27. The wirelessremote control kit of claim 24, wherein the plurality of weldingparameters includes current, voltage, inductance, and pulse commands.28. The wireless remote control kit of claim 24, wherein the wirelesscontrol communicated with the wireless receiver via one of a radiocontrol (RC), radio frequency (RF), cellular digital packet data, highspeed circuit switched data, packet data cellular, general packet radioservice, radio transmission technology, Bluetooth, IrDA, multichannelmultipoint distribution service, local multipoint distribution service,WiMAX, 802.11 Wi-Fi, infrared, UHF, NHF, and RIM.
 29. The wirelessremote control kit of claim 24, wherein the existing welding-typecontrol cable connection port is configured to engage both thewelding-type control cable and the wireless receiver via matching maleand female connectors.
 30. A method comprising: connecting a wirelessreceiver to a welding-type power source by way of an existingwelding-type control cable connection port located on an exterior of thewelding-type power source; wirelessly transmitting a signal from awireless remote control, wherein the signal is indicative of desiredoperational parameters of the welding-type power source; receiving thesignal remotely by way of the wireless receiver; and controlling thewelding-type power source in accordance with data embodied in thereceived wirelessly transmitted signal.
 31. The method of claim 30,wherein the desired operational parameters include at least one ofcurrent, voltage, inductance, pulse commands, voltage feedback, currentfeedback, and output activation.
 32. The method of claim 30, wherein thestep of wirelessly transmitting the signal includes the step ofwirelessly transmitting the signal via one of a radio control (RC),radio frequency (RF), cellular digital packet data, high speed circuitswitched data, packet data cellular, general packet radio service, radiotransmission technology, Bluetooth, IrDA, multichannel multipointdistribution service, local multipoint distribution service, WiMAX,802.11 Wi-Fi, infrared, UHF, VHF, and RIM.
 33. The method of claim 30,wherein the step of connecting the wireless receiver to the welding-typepower source by way of the existing welding-type control cableconnection port includes the step of connecting the wireless receivervia a 14-pin connector.
 34. The method of claim 30, wherein the existingwelding-type control cable connection port is configured to engage boththe welding-type control cable and the wireless receiver via matchingmale and female connectors.
 35. A wireless remote control kitcomprising: a wireless receiver configured to receive and relay a signalto a welding-type apparatus to control a plurality of welding parametersin the welding-type apparatus, wherein the wireless receiver isconfigured to be operatively connected to a controller housed in awelding-type power source of the welding-type apparatus by connection toan existing welding-type control cable connection port located on anexterior of the welding-type power source.
 36. The wireless remotecontrol kit of claim 35, wherein the existing welding-type control cableconnection port is a 14-pin connector.